Dual tandem flow diverter valve system

ABSTRACT

The invention is a dual tank dispensing system that provides for directional control of the fluid being dispensed. Flow may be diverted through various pathways in order to provide different flow modes including: normal delivery, backwashing, rinsing, and isolation of one of the tanks. A unique dual diverter valve unit provides for alternate flow arrangements through passages in a body that connect the two tanks to the source of water. Each valve is in connection with four passages and through rotation of these valves various pathways are created that lead the flow to be diverted through one or both tanks and through an outlet passage leading to the destination or through one of two passages that allow for either rinse or backwash. A detector may be used in connection with the control unit to determine that the filters are clogged and signals the system to being a backwashing operation. The control unit rotates one or both valves a certain degree that changes the direction of flow and allows a reverse flow through one of the tanks. Other movements of the valves may be used to direct the flow normally through the tank but not to the final destination (rinse mode) and/or shutting off flow to one tank entirely (disconnect mode).

BACKGROUND OF THE INVENTION

The invention relates to the field of dispensing and, in particular, todispensing systems that have a pair of intermediate filtering tanks thatprovide a filtering means for the liquid as it makes its way to a finaldestination, which may be e.g. domestic usage, pool water, etc. In suchsystems each tank acts as a separate filter so that one of the tanks maybe periodically removed from the system without having to interrupt thesupply of water as the other tank is used in its place.

Periodically, particles tend to build up on the filter whichnecessitates that the filter be backwashed (i.e. normal flow through thefilter be reversed) in order to clean the filter. It is such a step thatthe applicant's invention provides on an automatic basis and also on anas-needed basis when used with an external differential pressure sensor.Periodically, it may also be necessary to cut off the flow entirely fromone of the tanks in order to disconnect that tank for repair,replacement, etc. In that situation, the flow through the passages maybe diverted in order to direct flow entirely through the other tank andnot to the one being repaired.

DESCRIPTION OF THE PRIOR ART

While there are dual tank systems that for filtering liquid prior to itsfinal destination, none that applicant is aware of provide for automaticcontrol of steps for backwashing and rinsing the tanks on a periodicbasis.

SUMMARY OF THE INVENTION

A valve body having eight entrance passages connects the tanks to aliquid supply. Four of the passages are for entry and exit of liquidtrough each tank. One of the passages is the main entrance form thesource of liquid and other is for the exit of the liquid to the ultimatedestination. The other two passages are for discharge in either thebackwash or rinsing modes of operation. A pair of flow diverter valvesare fixed for rotation inside the valve body. Each diverter valve is inconnection with four of the passages in the valve body. In addition tothe entrance passages a central bore runs through the body in order toconnect each diverter valve to its own drive shaft in connection withthe controlling means.

In operation, a central controller operates on a time basis toperiodically go through backwash and rinse operations on alternatetanks. When such a step is necessary the controller rotates one or bothof the valve diverters in order change the normal flow of liquid throughthe tanks and the passages so that the flow through one of the tanks maybe reversed for backwash of the filter.

It is an object of the invention to provide a dual tank filter systemhaving flow diverting mechanism for reversing the flow of liquid througheither one of the tanks to provide a backwashing operation.

Another object of the invention is to provide a system that provides forthe automatic back washing of filters as the filters become clogged.

Another objective is to provide a dual tank filter system with automaticcontrol of modes of operation including the backwashing, rinsing anddisconnecting the tanks.

Yet another objective is to provide a dual tank filter system withsealing arrangements that prevent the buildup of particles inside thevalve passages.

Other objectives of the invention will become apparent to those skilledin the art once the invention has been shown and described.

DESCRIPTION OF FIGURES

FIG. 1A-G Basic flow patterns for various modes of operation.

FIG. 2 Valve body construction.

FIG. 3 Side view of inlet diverter and drive assembly.

FIG. 4 Side view or outlet diverter.

FIG. 5 End view of outlet diverter.

FIG. 6 View of inlet diverter and lugs.

FIG. 7 Front of valve body in relation to ports.

FIG. 8 Side view opposite FIG. 6.

FIG. 9 Drive means for valves.

FIG. 10 Control knob.

FIG. 11 A-G Flow patterns with detailed passages.

FIG. 12A-C Three basic flow patterns.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The overall construction of the valve body is shown in FIG. 2. The toppassage A is for the inlet of liquid (for both tanks) and the otherpassage B is for the outlet of liquid from either or both tanks. Both ofthese are located on the top surface of the block. The bottom passages Gand H allow for outlet of water in either the rinse or backwashingmodes. The four passages C, D, E, and F on the sides of the body allowfor entrance and exit of water to each of the tanks thus, there are fourof these, two passages for each tank including an exit and outlet forboth. Passage C is the outlet for tank 1, F is outlet for tank 2.Passage E. is inlet for tank 1, D is inlet for tank 2.

Any or all of the passages may be constructed so that they taper in thedirection toward the inside of the valve body so that the openings AAand BB of the diverter valve need only be of minimum size in order tocover the smaller passageway. It is preferred that these passageways belocated approximately 90° apart on the valve body as seen in FIG. 2.Other positions are possible without varying from the spirit of theinvention. For instance, if the ports are smaller in size, a smallerrotation of the diverter may be sufficient to connect the ports thatneed to be connected for that particular mode.

The two diverter valves 20 and 30 are located inside the center of thevalve body and are shown in detail in FIG. 3-6 and 8. Each diverter isof similar construction, both having a removed portion on the upper andlower portions of the cylindrical valve. The upper removed portion isdesignated AA and the lower removed portion designated BB. The upperremoved portion is about 200° of the circumference of the diverter andthe lower removed portion is about 135° of the divereter circumference.These portions allow the various passages A-H of the valve body to beconnected to one another in various patterns so that different flowpatterns may be obtained. Again if the ports are smaller in diameter,the removed portions may be smaller in size and still be able to coverthe ports effectively. For example. ports A and C and D may berelatively close to one another and may be unconnected as in FIG. 1A bya less than 200° removed portion. There may be a central passage 58 (seeFIGS. 12A and 3) leading through the center of one of the diverters andconnecting the two removed portions AA and BB to one another.

The size of the angle of the the removed portion will vary with the sizeand diameter of the central bore and port area. The valves may beconnected to one another through the use of lugs 2 in the outside of oneof the diverters. The lugs would connect with apertures 1 in the side ofthe other diverter. Thus the diverters can be connected to move togetherin a basic embodiment, although they may be connected so that they areout of phase in preferrred and alternate embodiments. I.e. the removedportions may not be aligned with one another, they may be positioned outof phase in relation co one another. In this way, the diverters may berotated by only one drive means. While both diverters are similar inconstruction, they are each in connection with different inlet openings.

It is also possible to have two separate drive means controlling thediverters. One way to do this would be by using two concentric shafts tooperate the diverters. I.e. the inlet diverter may be operated by oneshaft (hollow inside) and the outlet diverter may be operated separatelyby a shaft running through the center of the inlet diverter shaft. Eachshaft would have its own drive gear and drive motor contained in acentral controller.

The inlet diverter 20 is on one side of the interior passage seen inFIG. 2 so that it is in connection with the main inlet passage A as wellas tank inlet passages C and D and the backwash outlet G. Note thatthese letter designations for the inlets/outlets correspond to thosepassages shown in FIG.2. The outlet diverter 30 is on the other side ofinterior passage and connects passages B, E, F, and H, see FIG. 1 fordiagrammatic representation of these.

In normal operation (see FIG. 1G), the removed portion AA of thisdiverter connects the main inlet A with the two tank inlets C and D.Water (or other liquid) that goes to each tank is filtered and comes outof each of the tank outlet passages. The outlet diverter is positionedadjacent the inlet diverter so that the removed portion of the outletdiverter will connect the tank outlet passages E and F to the mainoutlet B and water then flows from the tanks to the ultimate destination(connected to the outlet passage B).

In the backwash mode (FIG. 1A and/or 1D), the inlet diverter is rotatedso that only one of the tank inlet passages (TIP) (that of the tank notbeing backwashed) is connected through AA to the main inlet opening andthe other tank inlet opening is connected to the backwash outlet throughBB. In FIG. 1A, inlet D remains connected to the main inlet A whileinlet C is connected to the backwash outlet G through the lower passageBB.

Note: the back wash outlet does not connect to the destination. It maybe connected to another container for removal of dirt, etc. or maysimply outlet on the ground. The outlet diverter is also rotated so thatone of the tank outlet passages (TOP) (that tank not being backwashed)is connected to the other tank outlet passage. In FIG. 1A this meansthat outlet F is connected to outlet E, E is now functioning as an inletfor tank 1 instead of its usual outlet function as in FIG. 1G. FIG. 1Dshows a similar operation the flow reversed i.e. tank 2 being backwashedand the inlet diverter valve being in a different position.

Thus in the backwash modes, the water comes in through the main inletand is sent to one of the tanks (that not being backwashed) in thenormal direction. This flow then leaves that tank and a regulatedportion of flow returns to the other tank (that being backwashed) in adirection opposite the normal flow direction. The reverse flow cleansout the filter and this dirt, etc. flows out the tank inlet passage andexits through the backwash passage by virtue of the position of theinlet diverter valve. See FIG. 1A and 1D.

In the rinsing mode FIG. 1C and 1F, the inlet diverter is in normal modeand flow enters the tank inlet passage C and D in the usual direction.The outlet diverter is rotated about 30° so that removed area BBconnects to the outlet passage H to outlet E. The outlet diverter wouldthen be rotated in the negative direction (i.e. -30° in this example) inorder to rinse the other tank. The inlet diverter remains in the sameposition throughout both operations, in fact the same position as in thenormal mode.

In the isolation mode FIG. 1B and 1E, the inlet diverter is rotated sothat the main inlet flow goes to the TIP (either C or D) for that tanknot being isolated and the other TIP receives no flow. The outletdiverter rotates so that the TOP (either E or F) of that tank not beingisolated remains in connection with the main outlet and the TOP of thetank being isolated does not connect with the main outlet (it is likelyto be connected to the rinse outlet allowing the tank to depressurize).The diverters are rotated in opposite directions to isolate the othertank i.e. if they were rotated 60° to isolate tank one they would rotate-60° to isolate tank two. In this mode, that tank that is isolated canbe removed from this system without affecting the flow.

In an alternate embodiment, the system may be modified slightly for usewith brine reservoirs in a water softener system, see FIG. 11. Eachfilter tank is a separate water softening system for removing mineralsout of water. Again, the water may be from any source e.g. well, etc.and is inlet at the main inlet A .

A brine solution is then used periodically to clean the resin matrixthat act as the filter means inside the tanks. The dissolved ions of thebrine solution exchange with minerals such as Calcium, magnesium etc.that are held in the matrix. After such exchange the sodium and chlorideions may be washed from the matrix and the matrix and in this manner theresin matrix is cleaned for reuse. Similar type process steps arecarried out as before with a backwash step identical to that previouslydescribed. There are two additional rinse steps, slow rinse and fastrinse which resemble the previous rinse step but is not identical. Theslow rinse step includes brine taken up from one of the brine resevoirs34, 35. This is drawn up by a pump in conjunction with an air checkvalve at 36. Brine wash is taken up at port 47 (FIG. 7A) by the suctionpulling effect of the eductors 30 and 32.

The first eductor line 30 is in connection with the outlet F of tank 2and the inlet C of tank 1. The second eductor 32 is in connection withthe inlet D of tank 2 and the outlet E of tank 1. One way valves 38 and39 are used at the point where the brine enters the eductor line toprevent reverse flow through the eductor during normal operation. Apassage 50 may be used to connect both ports G and H for better removalof back wash. The valve 44 may used in connection with this passage seeFIG. 11A etc.

When it is desired to clean the resin bed in tank 1 the backwash step isdone first, same as before see FIG. 11A. Then a slow rinse is done withthe valves in position akin to that for the isolation step described inthe first embodiment, see FIG. 11B. The brine solution is drawn upthrough air check valves 36 which then enters venturi at 47 and injectsat C of tank one. Usually there is a one to two ratio of water (fromtank 2) to brine (from the reservoir).

The back wash control valve 44 is closed during 11B and 11E brine/slowrinse to prevent brine from escaping at waste port 50 (see FIG. 11). Ahose may be connected to that port 50 (as well as G and H if manifold 45is not used) to aid in directing the waste stream. Valve 44 is operatedby a diverter mounted cam 42 (see FIG. 3 and 6). Sleeve 43 rides againstcam 42 which selectively compresses spring 48 to seat valve at portingmanifold 45. Channels 46 in manifold 45 connect venturis 30 and 32 todriving water suppplies and provide connection path between backwash andrinse ports via backwash control valve to a single waste port 50.

The slow rinse of brine exchanges the NaCl ions in the brine with ionstrapped by the resin bed in the tank. This leaves Na and Cl ions intheir place. The tank is then fast rinsed in a manner similar to therinse step described in the first embodiment, see FIG. 11C. No brinesolution is used and the fresh water from main inlet washes the SodiumChloride off of the matrix.

The same process may be used to clean the matrix of tank 2 with theeductor line 32 being used to draw the brine solution in during the slowrinse step. Again the steps are similar to those described in the firstembodiment, see FIG. 11D-F. Eventually both tanks may be returned toservice by normal configuration of the valves as shown in FIG. 11G.

A more basic process is shown in FIG. 12 with flow control orifices at49 to provide flow regulation of back wash port G and rinse port H. Theflow control device 58 is a passage shown in FIG. 3 and FIG. 12 andconnects sections AA and BB. The passage may be elastomeric to vary theflow in relation to the pressure of the stream. In FIG. 12 backwashcontrol valve 44 and manifold 46 may be omitted. Port H may be plugged.

In this set up, only three operational steps are needed to complete abackwash cycle for both tanks. The rinse steps are omitted. FIG. 12Bshows a +30° rotation of both diverters to connect TIP C to waste portG, and main outlet connects to TOP E via orifice 58 which regulates aportion of main outlet flow to supply water for back wash of first tank.By reversing diverter positions to -30° in FIG. 12C, the same result isachieved for filter tank two. Turn back to 0° and both filters resume online filter operation in 12A.

The controller is shown in FIGS. 9 and 10. The controller may beoperated by a timer that determines which modes should be performed. Thecontroller controls the movement of the diverter valves by rotating themthe necessary increment to reconnect the passages as needed. The controlmay be by a motor in connection with the right angle drive 22. Thisdrive turns a worm gear 2. The apertures 5 engage with the lugs 6 on thecontrol knob 7, see FIG. 3. The control knob is keyed to the couplingshaft at 13 in FIG. 9. The spring 9 presses against the control knob toinsure that the lugs remain engaged with the apertures. Cruciform shape15 allows coupling shaft 13 to removably engage inlet diverter to allowfor controller removal without valve disassembly.

In the preferred method of operation, the timer may go up to eight stepsto alternately backwash, isolate and rinse each of the tanks. Yetanother means of initiation may be of a timed interval on a daily basis.

A direct manual means may be used to over ride the automatic control ifneeded. The control knob may be pulled out for manual operation. Thisdisengages the lugs from the drive gear so that the control knob may beturned by hand. Alternate manual method allows valve operation by handcrank which directly drives the worm gear. Other means may be used todrive the diverter valves.

To initiate the automatic steps the controller may be activated by adifferential pressure sensor (DP) that can determine when a filter inone of the tanks is clogged. The DP sensor senses the summation offilter drop across both tanks. This sensor control can be used inaddition to the automatic control or may be used on its own.

I claim:
 1. A dual tank flow diverting system comprising: a valve blockhaving upper and lower surfaces, front and back surfaces and left andright surfaces, said block having an internal passage in connection withsaid front and back surfaces, a main inlet passage and a main outletpassage, said passages connecting said upper wall with said internalpassage, a left exit passage connecting said left wall and said internalpassage, a left inlet passage connecting said left wall with saidinternal passage, a right inlet passage connecting said right wall withsaid internal passages and a right exit passage connecting said rightwall with said internal passage, and two outlet passages connecting saidbottom wall with said internal passage, a first diverter valve fixed forrotation within said internal passage and having a removed portion forfluid connection with said left inlet passage, said right inlet passageand said main inlet passage, a second diverter valve fixed for rotationwithin said internal passage and having a removed portion for fluidconnection with said left exit passage, said right exit passage and saidmain outlet passage; said first diverter valve having a second removedportion extending about 135° around said first diverter valve.
 2. Theapparatus of claim 1 where said second diverter valve has a secondremoved portion extending about 135° around said second diverter valve.3. The apparatus of claim 1 wherein said second diverter valve has acentral passage in connection with said first and around said secondremoved portions.
 4. The apparatus of claim 1 wherein one of saiddiverters has at least one lug extending therefrom and the other of saiddiverters has at least one aperture adapted to engage said lug so thatsaid diverters may be controlled by a single means for rotation.
 5. Theapparatus of claim 1 wherein one of said secondary outlet passages is inconnection with a flow control means, and one of said diverters is inconnection with a means to operate said flow control means upon rotationof said diverter so that said flow control means may be operated byrotation of said diverter.
 6. The apparatus of claim 1 wherein saidsecondary outlet passages are both in connection with a common outletpassage.